EP2117280A1 - Dispositif de chauffage en ceramique, bougie de prechauffage utilisant le dispositif de chauffage en ceramique, et procede de fabrication du dispositif de chauffage en ceramique - Google Patents

Dispositif de chauffage en ceramique, bougie de prechauffage utilisant le dispositif de chauffage en ceramique, et procede de fabrication du dispositif de chauffage en ceramique Download PDF

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Publication number
EP2117280A1
EP2117280A1 EP08711793A EP08711793A EP2117280A1 EP 2117280 A1 EP2117280 A1 EP 2117280A1 EP 08711793 A EP08711793 A EP 08711793A EP 08711793 A EP08711793 A EP 08711793A EP 2117280 A1 EP2117280 A1 EP 2117280A1
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EP
European Patent Office
Prior art keywords
paste
heat
lead
ceramic heater
generating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP08711793A
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German (de)
English (en)
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EP2117280B1 (fr
EP2117280A4 (fr
Inventor
Norimitsu Hiura
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Kyocera Corp
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Kyocera Corp
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Publication date
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Publication of EP2117280A1 publication Critical patent/EP2117280A1/fr
Publication of EP2117280A4 publication Critical patent/EP2117280A4/fr
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Publication of EP2117280B1 publication Critical patent/EP2117280B1/fr
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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/18—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being embedded in an insulating material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23Q—IGNITION; EXTINGUISHING-DEVICES
    • F23Q7/00—Incandescent ignition; Igniters using electrically-produced heat, e.g. lighters for cigarettes; Electrically-heated glowing plugs
    • F23Q7/001—Glowing plugs for internal-combustion engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23Q—IGNITION; EXTINGUISHING-DEVICES
    • F23Q7/00—Incandescent ignition; Igniters using electrically-produced heat, e.g. lighters for cigarettes; Electrically-heated glowing plugs
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/42—Heating elements having the shape of rods or tubes non-flexible
    • H05B3/48—Heating elements having the shape of rods or tubes non-flexible heating conductor embedded in insulating material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23Q—IGNITION; EXTINGUISHING-DEVICES
    • F23Q7/00—Incandescent ignition; Igniters using electrically-produced heat, e.g. lighters for cigarettes; Electrically-heated glowing plugs
    • F23Q7/001—Glowing plugs for internal-combustion engines
    • F23Q2007/004—Manufacturing or assembling methods
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49082—Resistor making
    • Y10T29/49083—Heater type

Definitions

  • the present invention relates to ceramic heaters used as, for example, ignition heaters, flame detection heaters, sensor heaters, and heating heaters.
  • the ignition heaters and the flame detection heaters are used in the form of, for example, combustion devices such as combustion-type car heaters and kerosene fan heaters.
  • the sensor heaters are used in, for example, automotive glow plugs and various sensors such as oxygen sensors.
  • the heating heaters are used in, for example, measuring instruments.
  • a ceramic heater usually has a structure in which a heat-generating resistor and leads for feeding are arranged in a ceramic body.
  • the ceramic heater is manufactured in such a manner that the heat-generating resistor and the leads are separately formed, arranged to partly overlap with each other, and then fired together with the ceramic body.
  • a heat-generating resistor 3 is significantly misaligned with leads 5 or the stress applied thereto causes bumps 3c on the heat-generating resistor 3 as shown in Figs. 11A and 11B .
  • the bumps 3c have a sharp wedge shape, the bumps possibly causes cracks and/or the like in the heat-generating resistor and the leads.
  • the present invention has been made to solve the above problem. It is an object of the present invention to provide a ceramic heater in which the formation of such bumps are reduced and therefore cracks are reduced from being formed in a heat-generating resistor, leads, or a ceramic body.
  • a ceramic heater according to the present invention comprising a heat-generating resistor, configured for supplying power to the heat-generating resistor, a ceramic body containing the heat-generating resistor and the lead therein.
  • the heat-generating resistor comprises a connecting portion being connected to the lead and having a width less than the width of the lead, and a main heat-generating portion other than the connecting portion.
  • the lead comprises a recessed portion being located at end portion of the lead, being connected to the connecting portion, and being open at an only one side of the longitudinal direction of the lead and an only one side of the thickness direction of the lead. At least a part of the connecting portion is located inside the recessed portion.
  • a ceramic heater according to the present invention at least a part of connecting portion is located inside the recessed portion; hence, protrusion of the connecting portion is controlled. This is effective in that concentration of thermal stress on a single site is controlled during rapid heating or cooling or during firing or usage. A possibility of the formation of a crack is reduced in the heat-generating resistor, the lead, or a ceramic body near junctions between a heat-generating resistor and the lead. Therefore, the ceramic heater can be provided so as to be excellent in durability and reliability.
  • a ceramic heater 1 (hereinafter also referred to as the heater 1) according to a first embodiment of the present invention comprises a heat-generating resistor 3, lead 5 configured for supplying power to the heat-generating resistor 3, and a ceramic body 7 containing the heat-generating resistor 3 and the lead 5 therein.
  • the heat-generating resistor 3 comprises connecting portion 3a being connected to the lead 5 and having a width less than the width' of the lead 5, and a main heat-generating portion 3b other than the connecting portion 3a.
  • the lead 5 comprises a recessed portion 9 being located at end portion of the lead 5, being connected to the connecting portion 3a, and being open at an only one side of the longitudinal direction of the lead 5 and an only one side of thickness direction of the lead 5. At least a part of the connecting portion 3a is located inside the recessed portion 9.
  • a longitudinal direction, a thickness direction, and a width direction are defined as described below.
  • the longitudinal direction is defined as a direction that connects one end of lead, which extends substantially linearly, and the other end and that is parallel to the lead as shown in Fig. 1 .
  • the width direction is defined as a direction that connects the centers of the leads 5, which are adjacent to each other, in cross section that is perpendicular to the longitudinal direction and includes junctions between the connecting portion 3a and the lead 5 as shown in Fig. 2A .
  • the thickness direction is defined as a direction that is perpendicular to the width direction and the longitudinal direction.
  • a thickness and a width mean a length in the thickness direction and a length in the width direction, respectively.
  • the depth D of each recessed portion 9 is defined as the maximum length, in the thickness direction, between a surface portion of the recessed portion 9 and a line connecting two peaks X sandwiching the recessed portion 9 as shown in Fig. 2B , the two peaks X being portions of a corresponding one of the lead 5.
  • the lead 5 comprises a recessed portion 9 being open at an only one side of the longitudinal direction of the lead 5 and an only one side of the thickness direction of the lead 5. And at least a part of the connecting portion 3a is located in the recessed portion 9. This results in that a formation of bump on portion of the heat generating resister 3, which is connected to the leads 5 is controlled. Therefore, occurrence a crack as described above is controlled because it is controlled that thermal stresses concentrated on junction between the heat-generating resistor 3 and the lead 5 when the heat-generating resistor 3 and the lead 5 are rapidly heated or cooled during firing or usage.
  • the heat-generating resistor 3 is electrically connected to an anode-side electrode 13 and a cathode-side electrode 11 through the leads 5 and is further electrically connected to an external power supply (not shown) through the anode-side electrode 13 and the cathode-side electrode 11. Heat can be generated from the heat-generating resistor 3 in such a manner that a voltage is applied to the heat-generating resistor 3 from the external power supply.
  • the connecting portion 3a preferably has a width less than that of the main heat-generating portion 3b. This is because the possibility of the formation of a crack in the ceramic body 7 can be reduced. In particular, this is because the main heat-generating portion 3b can be designed to have a small thickness if the main heat-generating portion 3b is designed to have a uniform cross-sectional area and a large width such that a desired amount of heat is achieved.
  • the ceramic heater is generally manufactured in such a manner that a paste for forming the heat-generating resistor 3 and a paste for forming the lead 5 are sandwiched between a plurality of ceramic sheets for forming the ceramic body 7.
  • the adhesion between the ceramic sheets can be enhanced because the thickness of the main heat-generating portion 3b can be set to be small. Therefore, the possibility of the formation of a crack in the ceramic body 7 can be reduced.
  • the connecting portion 3a preferably has a width equal to 30% to 80% of that of the main heat-generating portion 3b.
  • the connecting portion 3a has a width equal to 30% or more of that of the main heat-generating portion 3b, the strength of junction between the main heat-generating portion 3b and the connecting portion 3a can be enhanced.
  • the connecting portion 3a has a width equal to 80% or less of that of the main heat-generating portion 3b, the adhesion between the ceramic sheets can be enhanced.
  • the connecting portion 3a has a width equal to that of the main heat-generating portion 3b
  • printing yield can be increased.
  • the heat-generating resistor 3 can be formed so as to have a constant width. Since the heat-generating resistor 3 has a simple shape when having such a constant width, the whole of the heat-generating resistor 3 can be readily formed by printing. This is effective in increasing printing yield.
  • the connecting portion 3a has a thickness less than that of the main heat-generating portion 3b. This is because the difference between the thickness of the main heat-generating portion 3b and the thickness of the lead 5 can be reduced. Therefore, the adhesion between the main heat-generating portion 3b, the lead 5, and the ceramic body 7 can be enhanced. This results in that a separation of the main heat-generating portion 3b, the lead 5, and the ceramic body 7 can be controlled from each other.
  • the connecting portion 3a preferably has a thickness L2 equal to 40% to 95% of the thickness L1 of the main heat-generating portion 3b.
  • the connecting portion 3a has a thickness L2 equal to 40% or more of the thickness L1 of the main heat-generating portion 3b, the bonding strength between the lead 5 and the connecting portion 3a can be enhanced.
  • the connecting portion 3a has a thickness L2 equal to 95% or less of the thickness L1 of the main heat-generating portion 3b, the connecting portion 3a can be readily placed in the recessed portion 9. This allows the adhesion between the connecting portion 3a and lead 5 to be enhanced.
  • the connecting portion 3a has a thickness L2 equal to the thickness L1 of the main heat-generating portion 3b
  • printing yield can be increased.
  • the heat-generating resistor 3 can be formed so as to have a constant thickness. Since the heat-generating resistor 3 has a simple shape when having such a constant thickness, the whole of the heat-generating resistor 3 can be readily formed by printing. This is effective in increasing printing yield.
  • the main heat-generating portion 3b has a thickness L1 substantially equal to the thickness L3 of the leads 5.
  • the fact that the main heat-generating portion 3b and the lead 5 have substantially the same thickness means that the difference in thickness between the main heat-generating portion 3b and the lead 5 is less than the thickness variation of the main heat-generating portion 3b and the thickness variation of the lead 5.
  • the connecting portion 3a preferably has a thickness less than that of the lead 5. This allows the heat-generating resistor 3 to have high resistance. The increase of the resistance of the heat-generating resistor 3 allows the main heat-generating portion 3b to efficiently generate heat and suppresses a increase the temperature of the lead 5 effectively.; hence, the durability of the ceramic heater 1 can be enhanced.
  • the connecting portion 3a preferably has a thickness L2 equal to 5% to 50% of the thickness L3 of the lead 5 as shown in Figs. 3 and 4 .
  • the connecting portion 3a has a thickness L2 equal to 5% or more of the thickness L3 of the lead 5
  • the bonding strength between the lead 5 and the connecting portion 3a can be enhanced.
  • the connecting portion 3a has a thickness L2 equal to 50% or less of the thickness L3 of the lead 5
  • the connecting portion 3a can be stably placed in the recessed portion 9. This results in that a protrusion of the connecting portion 3a from the recessed portion 9 is controlled effectively; hence, the formation of bump on the connecting portion 3a is controlled.
  • the connecting portion 3a is preferably substantially quadrilateral in cross section perpendicular to the longitudinal direction as shown in Fig. 2B .
  • the connecting portion 3a is substantially quadrilateral in cross section, the recessed portion 9 are allowed to be large. Therefore, this result in that a protrusion of the connecting portion 3a from the recessed portion 9 is controlled; hence, the possibility of the formation of bump on the connecting portion 3a is low. This results in that the formation of a crack near the connecting portion 3a can be controlled.
  • the heat-generating resistor 3 may be made of a carbide, nitride, or silicide of W, Mo, or Ti as a main component.
  • the heat-generating resistor 3 is preferably made of WC in view of the thermal expansion coefficient, heat resistance, and resistivity thereof.
  • the heat-generating resistor 3 preferably contains boron nitride.
  • a conductive component contained in the heat-generating resistor 3 usually has a thermal expansion coefficient greater than that of a ceramic component, such as silicon nitride, contained in the ceramic body 7. This causes stress between the heat-generating resistor 3 and the ceramic body 7.
  • boron nitride has a thermal expansion coefficient less than that of a ceramic component such as silicon nitride and hardly reacts with the conductive component in the heat-generating resistor 3. This allows the heat-generating resistor 3 to have a small thermal expansion coefficient without significantly varying heat-generating properties of the heat-generating resistor 3.
  • the content of boron nitride is preferably 4% to 20% by weight.
  • the thermal stress generated between the heat-generating resistor 3 and the ceramic body 7 can be reduced because the heat-generating resistor 3 has a small thermal expansion coefficient.
  • the boron nitride content is 20% by weight or less, varying the resistance of the heat-generating resistor 3 can be reduced. This allows the resistance of the heat-generating resistor 3 to be stable without significantly varying heat-generating properties of the heat-generating resistor 3.
  • the boron nitride content is more preferably 12% by weight or less.
  • the heat-generating resistor 3 contains the ceramic component, such as silicon nitride, contained in the ceramic body 7.
  • the ceramic component such as silicon nitride
  • the heat-generating resistor 3 preferably contains 10% to 40% by weight silicon nitride.
  • the leads 5 may be made of a carbide, nitride, or silicide of W, Mo, or Ti.
  • the leads 5 are preferably made of WC in view of the thermal expansion coefficient, heat resistance, and resistivity thereof.
  • the lead 5 be made of WC and contains 15% to 40% by weight silicon nitride.
  • the lead 5 contains 15% by weight or more silicon nitride, the difference between the thermal expansion coefficient of the lead 5 and the thermal expansion coefficient of the ceramic body can be reduced and therefore the formation of a crack between the lead 5 and the ceramic body can be controlled.
  • the lead 5 contains 40% by weight or less silicon nitride, increasing the resistance of the lead 5 can be reduced.
  • the content of silicon nitride therein is further more preferably 20% to 35% by weight.
  • the lead 5 and the heat-generating resistor 3 preferably contain the same main component. This allows the adhesion between the heat-generating resistor 3 and the lead 5 to be enhanced; hence, the possibility of the formation of a crack in junction between the heat-generating resistor 3 and the lead 5 can be reduced.
  • the ceramic body 7 may be made of, for example, an insulating ceramic material such as an oxide ceramic material, a nitride ceramic material, or a carbide ceramic material.
  • a ceramic material made of silicon nitride is preferably used. This is because the use of the ceramic material made of silicon nitride is effective in enhancing strength, toughness, electric insulation, and heat resistance. Such a ceramic material can be obtained as described below.
  • Silicon nitride which is a main component, is mixed with 3% to 12% by weight of a rare-earth element oxide, such as Y 2 O 3 , Yb 2 O 3 , and Er 2 O 3 , serving as a sintering aid; 0.5% to 3% by weight Al 2 O 3 ; and 1.5% to 5% by weight SiO 2 .
  • the mixture is formed into a predetermined shape and then fired at 1650°C to 1780°C by hot pressing.
  • the ceramic body 7 contains silicon nitride, MoSiO 2 or WSi 2 is preferably dispersed therein. This allows the ceramic body 7 to have an increased thermal expansion coefficient; hence, the difference in thermal expansion coefficient between the ceramic body 7 and the heat-generating resistor 3 can be reduced. This results in that the durability of the ceramic heater 1 can be enhanced.
  • connecting portion 3a is trapezoidal in cross section perpendicular to the longitudinal direction as shown in Fig. 5 . Since the connecting portion 3a is trapezoidal in cross section, the possibility of the formation of crack in the heat-generating resistor 3 or lead 5 can be more reduced than that described in the first embodiment. The reason for this is as described below.
  • the thermal expansion of a heat-generating resistor 3 causes thermal stress between the heat-generating resistor 3 and recessed portion 9 present in the lead 5.
  • the recessed portion 9 connected to the connecting portion 3a has side surfaces parallel to each other and therefore the directions of the thermal stresses applied to the parallel side surfaces of the recessed portion 9 are opposite to each other; hence, it is difficult to disperse the thermal stresses applied thereto.
  • the connecting portion 3a is trapezoidal and therefore such thermal stresses can be dispersed in the thickness direction (the vertical direction in Fig. 5 ). Since thermal stresses can be dispersed, the possibility of the formation of a crack in the heat generating resistor 3 and the leads 5 can be reduced.
  • recessed portion 9 is curved in cross section perpendicular to the width direction as shown in Fig. 6 .
  • surface of connecting portion 3a that is connected to the recessed portion 9 is curved. This prevents thermal stresses from being locally concentrated on the connecting portion 3a as compared to the first embodiment; hence, the possibility of the formation of a crack in the connecting portion 3a and the recessed portion 9 can be reduced.
  • the recessed portion 9 is preferably substantially arced in cross section perpendicular to the longitudinal direction shown in Figs. 7A and 7B .
  • This allows thermal stress to be substantially uniformly dispersed; hence, thermal stresses are prevented from being locally concentrated on the connecting portion 3a. This results in that the possibility of the formation of a crack in the connecting portions 3a and the recessed portion 9 can be reduced.
  • lead 5 has recessed portion 9 which are located at ends connected to two heat-generating resistors 3 and which are located at positions opposed to each other and the heat-generating resistors 3 each have connecting portions 3a partly located in the recessed portions 9 as shown in Fig. 8 . Therefore, the symmetry in temperature distribution between a portion and another portion of each heat-generating resistors 3 that are spaced from each other in the thickness direction is good; hence, the temperature variation of a heater 1 in the thickness direction during usage can be reduced. This results in that a formation of a crack in the heat-generating resistor 3 is controlled; hence, the ceramic heater 1 has enhanced durability.
  • the connecting portions 3a which are located in the recessed portions 9, preferably have substantially the same cross-sectional area. This allows the difference between the heat generated from one of the heat-generating resistors 3 and the heat generated from the other one to be reduced; hence, the difference between thermal stresses can be reduced.
  • the heat-generating resistors 3 preferably have a resistivity greater than the resistivity of the leads 5.
  • the resistance of the heat-generating resistors 3 can be adjusted to be greater than the resistance of the leads 5 without increasing the size of the heater 1. This allows the heat-generating resistors 3 to efficiently generate heat, thereby allowing the rapid heating of the ceramic heater 1.
  • the cathode-side electrodes 11 and the anode-side electrodes 13 can be prevented from being increased in temperature; hence, properties of the heater 1 can be enhanced.
  • the heat-generating resistors 3 can be measured for resistivity as described below.
  • each heat-generating resistor 3 When the cross-sectional area of each heat-generating resistor 3 is constant in the plane perpendicular to the longitudinal direction, the heat-generating resistor 3 is measured for resistance (m ⁇ ), cross-sectional area (mm 2 ), and length (mm). The resistance thereof can be measured with a milliohm meter such as Hioki 3541 Resistance HiTester.
  • the heat-generating resistor 3 may be machined with a surface grinder so as to have a shape with a cross-sectional area constant in an arbitrary direction.
  • a surface grinder is a surface grinder equipped with a KSK-type #250 diamond wheel available from Okamoto Kosaku Kikai. Examples of such a shape with a cross-sectional area constant in an arbitrary direction include a prismatic shape and a cylindrical shape.
  • the machined heat-generating resistor 3 may be measured for resistance (m ⁇ ), cross-sectional area (mm 2 ), and length (mm).
  • the lead 5 can be determined for resistivity by substantially the same method as that used to determine the resistivity of the heat-generating resistor 3.
  • the connecting portion 3a is preferably entirely located in the recessed portion 9.
  • the connecting portion 3a is entirely located in the recessed portion 9
  • the possibility of the formation of bump on the connecting portion 3a can be reduced. This results in that the formation of a crack near the connecting portion 3a is controlled; hence, the ceramic heater 1 has high durability and reliability.
  • the fact that the connecting portion 3a is entirely located in the recessed portion 9 means that the recessed portion 9 has a depth D greater than the thickness L2 of the connecting portion 3a.
  • the heat-generating resistor 3 comprises the main heat-generating portion 3b and the connecting portion 3a located at the end of the main heat-generating portion 3b.
  • the main heat-generating portion 3b preferably has a small thickness relatively to the width thereof, that is, the main heat-generating portion 3b is preferably flat in cross section perpendicular to the longitudinal direction. This allows the main heat-generating portion 3b to have a large perimeter in cross section perpendicular to the longitudinal direction and also allows the main heat-generating portion 3b to have a small thickness; hence, printing can be readily performed. Therefore, printing yield can be increased.
  • the main heat-generating portion 3b preferably has an elliptical shape, with the minor axis in the thickness direction, in cross section perpendicular to the longitudinal direction.
  • the main heat-generating portion 3b has a large width and a small thickness.
  • the main heat-generating portion 3b is elliptical in cross section, the main heat-generating portion 3b has curved surfaces; hence, thermal stresses can be prevented from being locally concentrated on the main heat-generating portion 3b.
  • the main heat-generating portion 3b preferably has substantially a uniform width.
  • the main heat-generating portion 3b can be readily formed; hence, printing yield can be increased.
  • locally generating heat in narrow portions thereof is controlled; hence, the ceramic heater 1 has enhanced durability.
  • the narrowest portion of the main heat-generating portion 3b preferably has a width equal to 70% or more of that of the widest portion of the main heat-generating portion 3b. When the narrowest portion has a width equal to 70% or more of that of the widest portion, locally generating heat in narrowest portions is controlled.
  • the main heat-generating portion 3b preferably has substantially a uniform thickness.
  • the main heat-generating portion 3b can be readily formed; hence, printing yield can be increased.
  • locally generating heat in thin portion thereof is controlled; hence, the ceramic heater 1 has enhanced durability.
  • the thinnest portion of the main heat-generating portion 3b preferably has a thickness equal to 80% or more of that of the thickest portion of the main heat-generating portion 3b.
  • the thinnest portion has a width equal to 80% or more of that of the thickest portion, locally generating heat in the thinnest portion is controlled.
  • the glow plug 15 of this embodiment comprises a ceramic heater 1 typified by that according to any one of the above embodiments, a first metal member 17 with a cylindrical shape, an end portion of the ceramic heater 1 is located in the first metal member 17, and a second metal member 19 located in the first metal member 17, spaced from the first metal member 17, and connected to the ceramic heater 1.
  • the heater 1 also comprises a cathode-side electrode 11 on a side surface thereof and an anode-side electrode 13 at an end thereof.
  • the cathode-side electrode 11 is electrically connected to the first metal member 17.
  • the anode-side electrode 13 is electrically connected to the second metal member 19.
  • the glow plug 15 of this embodiment can function as a heat source for engine starting. Since the glow plug 15 comprises the ceramic heater 1 of the above embodiments, the glow plug 15 has enhanced durability and reliability. Even if the glow plug 15 is used in cold climates, the glow plug 15 can start an engine in a shorter time as compared with conventional ones.
  • the method of manufacturing a ceramic heater of this embodiment comprises preparing a green form body 21 in such a manner that a first paste 4 for a heat-generating resistor 3 and a second paste 6 for a lead 5 are provided on green ceramic sheets for a ceramic body 7 and firing the green form body 21.
  • the first paste 4 has portions (hereinafter referred to as the connecting paste portion 4a) connected to the second paste 6.
  • the width of the connecting paste portion 4a is less than the width of the second paste 6 and the connecting paste portion 4a is located within the width of the second paste 6.
  • the first paste 4 is provided on the green ceramic sheets 8a and 8c by printing as shown in Fig. 10 .
  • the first paste 4 is provided on the sheets by printing such that the width of the connecting paste portion 4a is less than the width of the second paste 6.
  • the width of connecting portions 3a can be readily adjusted to be less than the width of the leads 5 in such a manner that plate making and a press mold are designed such that the width of the connecting paste portion 4a is less than the width of the second paste 6.
  • a third paste 23 for an anode-side electrode 13 and a cathode-side electrode 11 may be provided on the green ceramic sheets 8a and 8c by printing.
  • grooves be formed, in advance, in portions of the green ceramic sheets 8a and 8c that are to be provided with the first paste 4 and the first paste 4 be provided in the grooves. This is effective in that a misalignment of the first paste 4 is controlled.
  • the second paste 6 is provided on the green ceramic sheet 8b by printing. It is preferred that a groove or hole be formed, in advance, in a portion of the green ceramic sheet 8b that is to be provided with the second paste 6 and the second paste 6 be provided in the groove or hole. This is effective in that a misalignment of the second paste 6 is controlled.
  • the green form body 21 is prepared in such a manner that the green ceramic sheets 8a and 8c provided with the first paste 4 and the green ceramic sheet 8b provided with the second paste 6 are stacked such that the connecting paste portion 4a are provided within the width of the second paste 6.
  • the green form body 21 is fired at a temperature of 1650°C to 1780°C by hot pressing. This allows the ceramic heater 1 of this embodiment to be manufactured.
  • the formation of a bump on the connecting portion 3a is controlled by using of the ceramic heater-manufacturing method of this embodiment. This results in that the possibility of the formation of a crack in the ceramic body 7, the heat-generating resistor 3, or the lead 5 is reduced.
  • the ceramic heater 1 which is rectangular parallelepiped-shaped after being fired, may be subjected to centerless grinding so as to be cylindrical.
  • the ceramic heater 1 can be manufactured so as to have such a shape as shown in Fig. 1 in such a manner that one end portion and another end portion of the ceramic heater 1 are machined with a diamond wheel machined into a desired shape in advance.
  • the green ceramic sheets 8a and 8c provided with the first paste 4 and the green ceramic sheet 8b provided with the second paste 6 are stacked. These sheets may be stacked as described below.
  • the first paste 4 is provided on the green ceramic sheets 8a and 8c by printing.
  • the second paste 6 is provided on the green ceramic sheets 8a and 8c by printing.
  • the green ceramic sheets 8a and 8c provided with the first paste 4 and the second paste 6 are stacked with the green ceramic sheet 8b.
  • first paste 4 and the second paste 6 are provided on the green ceramic sheets 8, which are of the same type, and the green ceramic sheets 8 are then stacked, misalignment between the element comprising the first paste 4 and the element comprising the second paste 6 can be controlled.
  • the width of the first paste 4 is preferably adjusted such that the width of the connecting paste portions 4a is less than that of the other portion of the first paste (hereinafter referred to as the main heat-generating paste portion 4b).
  • the main heat-generating portion 3b can be designed to have a small thickness by increasing the width of the main heat-generating paste portion 4b.
  • the reduction of the thickness of the main heat-generating portion 3b allows the adhesion between the green ceramic sheets to be enhanced.
  • the main heat-generating portion 3b has a small thickness, the main heat-generating portion 3b can be readily printed; hence, printing yield can be increased.
  • the connecting paste portions 6b preferably have a width equal to 30% to 80% of the width of the main heat-generating paste portion 6a.
  • the connecting paste portions 6b have a width equal to 30% or more of the width of the main heat-generating paste portion 6a, the strength at the boundaries between the main heat-generating portion 3b and the connecting portions 3a can be enhanced.
  • the contact area between the connecting paste portions and the second paste is increased; hence, the bonding strength between the connecting portions 3a and the leads 5 can be enhanced.
  • the connecting paste portions 6b have a width equal to 80% or less of the width of the main heat-generating paste portion 6a, the adhesion between the ceramic sheets can be enhanced.
  • the width of the connecting paste portions 4a is less than the width of the main heat-generating paste portion 4b. This is because the difference in thickness between the main heat-generating portion 3b and the leads 5 can be reduced. Hence, a separation of the main heat-generating portion 3b and the lead 5 from the ceramic body 7 is controlled.
  • the connecting paste portion 4a preferably has a thickness equal to 40% to 95% of the thickness of the main heat-generating paste portion 4b.
  • the connecting paste portion 4a have a thickness equal to 40% or more of the thickness of the main heat-generating paste portion 4b, the bonding strength between the second paste 6 and the connecting paste portion 4a can be enhanced.
  • the connecting paste portion 4a have a thickness equal to 95% or less of the thickness of the main heat-generating paste portion 4b, the connecting paste portion 4a can be readily placed in recessed portion 9. This allows the connecting paste portion 4a and the second paste 6 to be securely connected to each other.
  • the thickness of the connecting paste portion 4a is less than the thickness of the second paste 6. This is because the resistance of the heat-generating resistor 3 can be increased. The increase of the resistance of the heat-generating resistor 3 allows the main heat-generating portion 3b to efficiently generate heat.
  • the connecting paste portion 4a preferably has a thickness equal to 5% to 50% of the thickness of the second paste 6.
  • the connecting paste portion 4a has a thickness equal to 5% or more of the thickness of the second paste 6, the bonding strength between the second paste 6 and the connecting paste portion 4a can be enhanced.
  • the connecting paste portion 4a have a thickness equal to 50% or less of the thickness of the second paste 6, the connecting paste portion 4a can be entirely placed in recessed portions 9 stably. This results in that a protrusion of the connecting paste portion 4a from the recessed portion 9 is controlled effectively; hence, the possibility of the formation of a bump on the connecting portion 3a can be reduced.
  • the second paste 6 has the recessed portion 9 and the first paste 4 is connected to the second paste 6 in the recessed portion 9.
  • the misalignment of the connecting paste portion 4a can be controlled; hence, the connecting paste portion 4a can be stably provided in the recessed portion 9.
  • the recessed portion 9 can be formed by press molding using, for example, a mold with a predetermined shape.
  • a mold with a predetermined shape In particular, the following mold may be used: a mold designed such that the recessed portion 9 is formed in end portions of the second paste 6 so as to be open in the longitudinal direction and the thickness direction.
  • the lead 5 can be formed so as to have the recessed portion 9, which are open in the longitudinal direction and the thickness direction, in such a manner that the second paste 6 press-molded with the mold is provided on the green ceramic sheets 8 and then fired.
  • the ceramic heater 1 of the above embodiment was prepared as described below.
  • a mixture was prepared by adding an oxide of Yb and MoSi 2 to a powder made of silicon nitride (Si 3 N 4 ) as a main component.
  • the Yb oxide was used as a sintering aid.
  • MoSi 2 was used to adjust the thermal expansion coefficient of green ceramic sheets close to the thermal expansion coefficient of heat-generating resistors 3 and leads 5.
  • the mixture was press-molded into the green ceramic sheets 8.
  • the first paste 4, the second paste 6, and the third paste 23 for an electrode lead portions were prepared.
  • the first paste 4, the second paste 6, and the third paste 23 prepared from the same material made of WC and boron nitride as a main component.
  • the first paste 4 and third paste 23 were provided on the green ceramic sheets 8 by printing.
  • the first paste 4 was provided thereon so as to vary in width and thickness as shown in Table 1 below.
  • the first paste 4 was provided thereon such that a main heat-generating portion 3b had a width of 0.6 to 1.0 mm and a thickness of 0.10 to 0.25 mm and connecting portions 3a had a width of 0.6 to 1.0 mm and a thickness of 0.07 to 0.19 mm.
  • the second paste 6 was provided on the green ceramic sheets 8 by printing. In this operation, the second paste 6 was provided thereon such that the leads 5 had a width of 1.0 mm and a thickness of 1.0mm.
  • recessed portions 9 were formed in end portions of the leads 5 with a press mold so as to be open in the longitudinal direction and the thickness direction, the end portions being connected to the connecting portions 3a.
  • the recessed portions 9 had a depth D of 0.20 mm.
  • the recessed portions 9 were quadrilateral ( Fig. 2A ), tapered ( Fig. 5 ), curved ( Fig. 6 ), or substantially arced ( Fig. 7A ).
  • Green form body 21 was prepared as described above.
  • Each green form body 21 was provided in a cylindrical carbon mold and then fired at a temperature of 1650°C to 1780°C and a pressure of 30 to 50 MPa in a reducing atmosphere by hot pressing, whereby a sintered body was obtained. Electrode metal members were brazed to a cathode-side electrode 11 and anode-side electrode 13 exposed at the surface of the sintered body, whereby the ceramic heater 1 was prepared.
  • the heat-generating resistors 3 and the leads 5 were measured for resistivity by a procedure below.
  • Sintered bodies were prepared from a material for forming the heat-generating resistors 3 and a material for forming the leads 5. Each sintered body was ground into a 3-mm square prism with a length of 18 mm using a surface grinder equipped with a #250 diamond wheel. Electrodes were formed on both end surfaces of the sintered body by printing and then baked in a vacuum furnace.
  • the sintered body was measured for resistance R (m ⁇ ) with Hioki 3541 Resistance HiTester in such a manner that a constant current was applied between the electrodes at room temperature.
  • the heat-generating resistors 3 had a resistivity of 1.6 to 2.5 ⁇ m and the leads 5 had a resistivity of 2.5 ⁇ m.
  • the reason why these sintered bodies were prepared from the material for forming the heat-generating resistors 3 in this example is to readily measure the resistivity.
  • Table 1 summarizes the width, thickness, and resistivity of the main heat-generating portions 3b, connecting portions 3a, and leads 5 of the samples.
  • the ceramic heater 1 was subjected to a heat cycle durability test below.
  • the ceramic heater 1 was supplied with electricity for 30 seconds, whereby the ceramic body 7 was heated such that the surface temperature of the ceramic body 7 was increased from room temperature up to 1300°C.
  • the resulting ceramic heater 1 was air-cooled for 60 seconds, whereby the surface temperature of the ceramic body 7 was decreased to room temperature.
  • the ceramic heater 1 was heated and cooled for 140000 cycles.
  • the surface temperature of the ceramic body 7 may be measured with a radiation thermometer.
  • the resistance of the ceramic heater 1 was adjusted such that the voltage applied to the ceramic heater 1 to maintain the ceramic heater 1 at 1300°C was 190 to 210 V.
  • samples comprise main heat-generating portions 3b and connecting portions 3a having different widths, thicknesses, resistivities, and shapes were evaluated for printing yield.
  • the fired samples were evaluated for cracks.
  • the samples subjected to the heat cycle test were evaluated for cracks.
  • the samples were observed with an optical microscope at a magnification of 450 times whether cracks were present or not.
  • Samples 1 and 2 have sharp wedge-shaped bumps protruding in the width direction because the connecting portions 3a of the heat-generating resistors 3 were formed so as to have the same width as that of the leads 5. Therefore, the ceramic body 7 has a high crack incidence of 60% or more.
  • the ceramic heaters 1 of Samples 3 to 15 have a crack incidence of 20% or less. This confirms that a crack incidence thereof is greatly improved because the connecting portions 3a have a width less than that of the leads 5 and therefore the thermal stresses applied thereto are reduced.
  • the recessed portions 9 are curved or substantially arced, the leads have the recessed portions located in end portions which are connected to the connecting portions and which are opposed to each other, and the connecting portions are entirely located in the recessed portions. Cracks are hardly present in Samples 5 to 7, 10, and 12, which are fired or subjected to the durability test. This shows that the ceramic heaters have significantly enhanced durability.
  • Samples 4 and 11 in which the main heat-generating portions 3b have a large thickness have a relatively small printing yield of 60% to 70%. This is probably because, since the main heat-generating portions 3b have a large thickness and therefore are forced to be printed, the difference in thickness therebetween is large.
  • Sample 4 in which the connecting portions 3a have a width greater than that of the main heat-generating portion 3b has a low printing yield of 60%.
  • Samples 3, 4, and 11, in which the connecting portions 3a have a large thickness have relatively high crack incidence. This is because the connecting portions 3a are badly located in the recessed portions 9 of the leads 5.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Resistance Heating (AREA)
  • Surface Heating Bodies (AREA)
EP08711793.3A 2007-02-22 2008-02-22 Dispositif de chauffage en ceramique, bougie de prechauffage utilisant le dispositif de chauffage en ceramique, et procede de fabrication du dispositif de chauffage en ceramique Active EP2117280B1 (fr)

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JP2007041681 2007-02-22
PCT/JP2008/053019 WO2008105327A1 (fr) 2007-02-22 2008-02-22 Dispositif de chauffage en céramique, bougie de préchauffage utilisant le dispositif de chauffage en céramique, et procédé de fabrication du dispositif de chauffage en céramique

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US20110114622A1 (en) * 2008-02-20 2011-05-19 Ngk Spark Plug Co., Ltd. Ceramic heater and glow plug
EP2704518A1 (fr) * 2011-04-27 2014-03-05 Kyocera Corporation Élément chauffant et bougie à incandescence le comportant
EP2704519A1 (fr) 2011-04-27 2014-03-05 Kyocera Corporation Élément chauffant et bougie incandescente comprenant ledit élément
WO2016096519A1 (fr) * 2014-12-18 2016-06-23 Robert Bosch Gmbh Élément électrique chauffant et mise en contact présentant une durabilité améliorée
EP2600688A4 (fr) * 2010-07-30 2018-01-17 Kyocera Corporation Élément chauffant et sa bougie de préchauffage
EP2635090A4 (fr) * 2010-10-27 2018-01-17 Kyocera Corporation Réchauffeur et bougie à incandescence munie de celui-ci
EP3151630A4 (fr) * 2014-05-27 2018-01-24 Kyocera Corporation Dispositif de chauffage en céramique et dispositif d'allumage doté de ce dernier

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JP5642260B2 (ja) * 2011-02-28 2014-12-17 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
JP5829443B2 (ja) * 2011-06-27 2015-12-09 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
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JP5403017B2 (ja) * 2011-08-30 2014-01-29 株式会社デンソー セラミックヒータ及びそれを用いたガスセンサ素子
JP5864301B2 (ja) * 2012-02-27 2016-02-17 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
CN102616036B (zh) * 2012-04-10 2013-12-25 无锡隆盛科技股份有限公司 能降低片式氧传感器起燃时间的加热器的制造方法
EP2840313B1 (fr) * 2012-04-20 2018-08-08 NGK Sparkplug Co., Ltd. Bougie à incandescence
CN104396342B (zh) * 2012-06-29 2016-02-24 京瓷株式会社 加热器及具备该加热器的电热塞
JP6105464B2 (ja) * 2013-12-27 2017-03-29 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
EP3136819B1 (fr) * 2014-04-25 2020-05-06 Kyocera Corporation Dispositif de chauffage et dispositif d'allumage
JP6023389B1 (ja) * 2014-12-25 2016-11-09 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
JP6483512B2 (ja) * 2015-04-21 2019-03-13 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
JP6957663B2 (ja) * 2015-04-22 2021-11-02 京セラ株式会社 セラミックヒータ
KR101888746B1 (ko) 2015-09-10 2018-08-14 니혼도꾸슈도교 가부시키가이샤 세라믹 히터 및 글로 플러그
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JP6014232B2 (ja) * 2015-10-23 2016-10-25 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
JP6085050B2 (ja) * 2016-03-25 2017-02-22 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
JP6224797B2 (ja) * 2016-09-23 2017-11-01 京セラ株式会社 ヒータおよびこれを備えたグロープラグ
JP6272519B2 (ja) * 2017-01-26 2018-01-31 京セラ株式会社 ヒータおよびこれを備えたグロープラグ

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Publication number Priority date Publication date Assignee Title
US20100288747A1 (en) * 2007-10-29 2010-11-18 Kyocera Corporation Ceramic heater and glow plug provided therewith
US20110114622A1 (en) * 2008-02-20 2011-05-19 Ngk Spark Plug Co., Ltd. Ceramic heater and glow plug
US8378273B2 (en) * 2008-02-20 2013-02-19 Ngk Spark Plug Co., Ltd. Ceramic heater and glow plug
EP2600688A4 (fr) * 2010-07-30 2018-01-17 Kyocera Corporation Élément chauffant et sa bougie de préchauffage
EP2635090A4 (fr) * 2010-10-27 2018-01-17 Kyocera Corporation Réchauffeur et bougie à incandescence munie de celui-ci
EP2704518A1 (fr) * 2011-04-27 2014-03-05 Kyocera Corporation Élément chauffant et bougie à incandescence le comportant
EP2704518A4 (fr) * 2011-04-27 2014-10-22 Kyocera Corp Élément chauffant et bougie à incandescence le comportant
US9491805B2 (en) 2011-04-27 2016-11-08 Kyocera Corporation Heater and glow plug provided with same
EP2704519A4 (fr) * 2011-04-27 2014-10-01 Kyocera Corp Élément chauffant et bougie incandescente comprenant ledit élément
EP2704519A1 (fr) 2011-04-27 2014-03-05 Kyocera Corporation Élément chauffant et bougie incandescente comprenant ledit élément
US10299317B2 (en) 2011-04-27 2019-05-21 Kyocera Corporation Heater and glow plug provided with same
EP3151630A4 (fr) * 2014-05-27 2018-01-24 Kyocera Corporation Dispositif de chauffage en céramique et dispositif d'allumage doté de ce dernier
WO2016096519A1 (fr) * 2014-12-18 2016-06-23 Robert Bosch Gmbh Élément électrique chauffant et mise en contact présentant une durabilité améliorée

Also Published As

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EP2117280B1 (fr) 2018-04-11
JP4969641B2 (ja) 2012-07-04
WO2008105327A1 (fr) 2008-09-04
JPWO2008105327A1 (ja) 2010-06-03
US20090320782A1 (en) 2009-12-31
CN101647314A (zh) 2010-02-10
KR20090111805A (ko) 2009-10-27
EP2117280A4 (fr) 2014-08-06
CN101647314B (zh) 2012-05-23
KR101441595B1 (ko) 2014-09-19

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